US20100193029A1 - Solar Module with Encapsulated Edge - Google Patents
Solar Module with Encapsulated Edge Download PDFInfo
- Publication number
- US20100193029A1 US20100193029A1 US12/636,689 US63668909A US2010193029A1 US 20100193029 A1 US20100193029 A1 US 20100193029A1 US 63668909 A US63668909 A US 63668909A US 2010193029 A1 US2010193029 A1 US 2010193029A1
- Authority
- US
- United States
- Prior art keywords
- edge
- solar module
- encapsulation
- support
- tracking distance
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000005538 encapsulation Methods 0.000 claims abstract description 64
- 239000006096 absorbing agent Substances 0.000 claims abstract description 21
- 239000011521 glass Substances 0.000 claims description 37
- 230000002093 peripheral effect Effects 0.000 claims description 29
- 230000001815 facial effect Effects 0.000 claims description 21
- 238000009432 framing Methods 0.000 claims description 13
- 238000000034 method Methods 0.000 claims description 12
- 229920003023 plastic Polymers 0.000 claims description 8
- 239000004033 plastic Substances 0.000 claims description 8
- 229920001971 elastomer Polymers 0.000 claims description 6
- 239000005060 rubber Substances 0.000 claims description 6
- 238000001125 extrusion Methods 0.000 claims description 2
- 238000001746 injection moulding Methods 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 claims description 2
- 229920002943 EPDM rubber Polymers 0.000 description 4
- 238000002347 injection Methods 0.000 description 4
- 239000007924 injection Substances 0.000 description 4
- 229920002725 thermoplastic elastomer Polymers 0.000 description 4
- 230000004888 barrier function Effects 0.000 description 3
- 239000004065 semiconductor Substances 0.000 description 3
- 239000012815 thermoplastic material Substances 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 230000005611 electricity Effects 0.000 description 2
- 208000015943 Coeliac disease Diseases 0.000 description 1
- 229910004205 SiNX Inorganic materials 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052681 coesite Inorganic materials 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 229910052682 stishovite Inorganic materials 0.000 description 1
- 229910052905 tridymite Inorganic materials 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10165—Functional features of the laminated safety glass or glazing
- B32B17/10293—Edge features, e.g. inserts or holes
- B32B17/10302—Edge sealing
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
- B32B17/10036—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
- H01L31/0488—Double glass encapsulation, e.g. photovoltaic cells arranged between front and rear glass sheets
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- This invention relates to a solar module with encapsulated edge and the methods of making it.
- Solar modules have photovoltaic devices to generate electricity. Photovoltaic devices are formed between the front glass and the back glass of the solar module and edge-sealed.
- the tracking distance is the distance between the edge of the photovoltaic device and the outer edge of the seal. For reasons of safety, a certain tracking distance is required, which will make the peripheral portion of the solar module unusable.
- an edge-encapsulated solar module may include a solar module and an encapsulation frame.
- the solar module has a back support, a front support, and an absorber layer between the front support and the back support.
- the encapsulation frame surrounding the solar module, where the encapsulation frame contacts an edge portion of the back support and an edge portion of the front support.
- the encapsulation frame may additionally contact a peripheral edge portion of a facial surface of the front support and a peripheral edge portion of a facial surface of the back support.
- the back and front support can include glass respectively.
- the encapsulation frame can include rubber, plastic, thermoplastic elastomer, or EPDM rubber.
- a first tracking distance of solar module is a distance along a surface of the back support between an edge of the encapsulation and an edge of the absorber layer
- a second tracking distance is a distance along a surface of the front support between an edge of the encapsulation and an edge of the absorber layer.
- the first tracking distance and the second tracking distance can be at least 4 millimeters, about 4 millimeters to 50 millimeters, about 4 millimeters to 16 millimeters, or about 10 millimeters.
- a method of making an edge-encapsulated solar module includes framing a photovoltaic device with an encapsulation frame contact an edge portion of each of a front support, the back support, and the photovoltaic device.
- the method can further include forming an absorber layer on the first support and positioning the second support on the absorber layer.
- the framing can include injection molding the encapsulation frame.
- the framing can include plastic extrusion of the encapsulation frame.
- the back and front support can include glass respectively.
- the framing can include covering a peripheral edge portion of each of the first support, the photovoltaic device, and the second support with rubber, plastic, thermoplastic elastomer, or EPDM rubber.
- the framing can further include a step of positioning a first edge of the encapsulation at a predetermined first tracking distance from the photovoltaic device, wherein the first tracking distance is a distance along a surface of the back support between an edge of the encapsulation and an edge of the absorber layer.
- the framing can further include a step of positioning a second edge of the encapsulation at a predetermined second tracking distance from the photovoltaic device, wherein the second tracking distance is a distance along a surface of the front support between an edge of the encapsulation and an edge of the absorber layer.
- the first tracking distance and the second tracking distance can be at least 4 millimeters, about 4 millimeters to 50 millimeters, about 4 millimeters to 16 millimeters, or about 10 millimeters.
- FIG. 1 is a cross-sectional view of an embodiment of a solar module with encapsulated edge.
- FIG. 2 is a perspective view of an embodiment of a solar module with encapsulated edge shown in FIG. 1 .
- FIG. 3 is a cross-sectional view of an embodiment of a solar module with encapsulated edge.
- FIG. 4 is a vertical cross-sectional view taken through an injection mold of the present invention, and illustrates upper and lower mold bodies in their open position with each defining a cavity portion which in the closed position of the mold defines a mold cavity for forming the encapsulation of the instrument cover of FIG. 1 .
- FIG. 5 is a vertical cross-sectional view taken through the mold of FIG. 4 , and illustrates the solar module positioned upon the lower mold body incident to the closing of the mold bodies.
- FIG. 6 is a vertical cross-sectional view of the mold of FIGS. 4 and 5 , and illustrates the mold in its closed position and a peripheral cavity defined thereby into which projects a peripheral edge of the solar module.
- FIG. 7 is a vertical cross-sectional view of the mold of FIGS. 4 through 6 , and illustrates thermoplastic material injected into the cavity and encapsulating an edge of the solar module to form a continuous encapsulation.
- the solar module is framed with an encapsulation.
- the tracking distance can be added up along the surface of front glass or back glass to the required distance. Therefore, the photovoltaic device can be brought closer to the edge of the glass, resulting in higher efficiency of the solar module.
- an edge-encapsulated solar module 5 may include a back support such as back glass 6 , a front support such as front glass 2 , and a photovoltaic device 4 , which can include a semiconductor absorber layer that converts solar energy to electricity.
- the back glass 6 has a second facial surface 3 of the solar module 5 .
- the front glass 2 has a first facial surface 1 of the solar module 5 .
- the back glass 6 can have an edge 22 .
- the front glass 2 can have an edge 21 .
- the photovoltaic device 4 can be formed between the back glass 6 and the front glass 2 .
- the photovoltaic device 4 can have an edge 7 .
- the edge-encapsulated solar module 5 can have a peripheral encapsulation frame 8 .
- the encapsulation frame 8 can form a frame surrounding the solar module 5 .
- the encapsulation frame 8 can encapsulate peripheral edge portions 19 and 20 of the first facial surface 1 and the second facial surface 3 of the solar module 5 respectively.
- the encapsulation frame 8 can seal the edge 7 of the photovoltaic device 4 .
- the encapsulation frame 8 can also encapsulate the edges 22 and 21 of the back glass 6 and the front glass 2 of the solar module 5 respectively.
- the encapsulation frame 8 may cover a minimal portion of the first facial surface 1 of the front glass 2 of the photovoltaic module 5 so as not to diminish the efficiency of the module while protecting the module edge.
- the encapsulation frame 8 can be made of plastic, rubber, or thermoplastic elastomer, such as ethylene-vinyl acetate (EVA). In a certain embodiment, the encapsulation frame 8 can be made of EPDM rubber
- a first tracking distance is the distance from the point where encapsulation frame 8 meets second facial surface 3 , along first facial surface 3 to edge 22 , then along edge 22 to absorber layer edge 7 .
- the first tracking distance created when encapsulation frame 8 is installed is a minimum distance along which an electrical charge would have to travel to reach a person or component contacting back glass 6 of solar module 5 .
- the first tracking distance can be determined by the design of encapsulation frame 8 .
- the first tracking distance can be at least 4 mm, for example in the range of about 4 mm to about 50 mm.
- the first tracking distance can be from about 4 mm to about 16 mm.
- the first tracking distance can be about 10 mm.
- a second tracking distance is the distance from the point where encapsulation frame 8 meets first facial surface 1 , along second facial surface 1 to edge 21 , then along edge 21 to absorber layer edge 7 .
- the second tracking distance created when encapsulation frame 8 is installed is a minimum distance along which an electrical charge would have to travel to reach a person or component contacting front glass 2 of solar module 5 .
- the second tracking distance can be determined by the design of encapsulation frame 8 .
- the second tracking distance can be at least 4 mm, for example in the range of about 4 mm to about 50 mm.
- the second tracking distance can be from about 4 mm to about 16 mm.
- the second tracking distance can be about 10 mm.
- an edge-encapsulated solar module 17 may include a back support, such as back glass 13 , a front support, such as front glass 10 , a photovoltaic device 11 including a semiconductor absorber layer, and an additional layer 12 .
- the layer 12 can be a semiconductor layer.
- the layer 12 can be a barrier layer, such as a SiO 2 barrier layer or a SiN x barrier layer.
- the front glass 10 has a first facial surface 9 of the solar module 17 .
- the front glass 10 can have an edge 24 .
- the back glass 13 has a second facial surface 14 of the solar module 17 .
- the back glass 13 can have an edge 25 .
- the first photovoltaic device 11 and the additional layer 12 can be formed between the back glass 13 and the front glass 10 .
- First photovoltaic device 11 can have an edge 16 .
- the additional layer 12 can have an edge 15 .
- the edge-encapsulated solar module 17 can have a peripheral encapsulation frame 18 .
- the encapsulation frame 18 can form a frame surrounding the solar module 17 .
- the encapsulation frame 18 can cover peripheral edge portions 23 and 26 of the first surface 9 and the second surface 14 of the solar module 17 respectively.
- the encapsulation frame 18 can seal the edge 16 of first photovoltaic device 11 and the edge 15 of layer 12 .
- Encapsulation frame 18 can also seal the edges 25 and 24 of the back glass 13 and the front glass 10 of the solar module 17 respectively.
- the encapsulation frame 18 may cover a minimal portion of the first surface 9 of the front glass 10 of photovoltaic module 17 so as not to diminish the efficiency of the module while protecting the panel edge.
- the encapsulation frame 18 can be made of plastic, rubber, or thermoplastic elastomer. In a certain embodiment, the encapsulation frame 18 can be made of EPDM rubber.
- a first tracking distance is the distance from the point where encapsulation frame 18 meets second facial surface 14 , along second facial surface 14 to edge 25 , then along edge 25 to additional layer edge 15 , along additional layer edge 15 to photovoltaic device 11 , to the absorber layer.
- the first tracking distance created when encapsulation frame 18 is installed is a minimum distance along which an electrical charge would have to travel to reach a person or component contacting back glass 13 of solar module 17 .
- the first tracking distance can be determined by the design of encapsulation frame 18 .
- the first tracking distance can be at least 4 mm, for example in the range of about 4 mm to about 50 mm.
- the first tracking distance can be from about 4 mm to about 16 mm.
- the first tracking distance can be about 10 mm.
- a second tracking distance is the distance from the point where encapsulation frame 18 meets first facial surface 9 , along first facial surface 9 to edge 24 , then along edge 24 to absorber layer edge 16 .
- the second tracking distance created when encapsulation frame 18 is installed is a minimum distance along which an electrical charge would have to travel to reach a person or component contacting front glass 10 of solar module 17 .
- the second tracking distance can be determined by the design of encapsulation frame 18 .
- the second tracking distance can be at least 4 mm, for example in the range of about 4 mm to about 50 mm.
- the second tracking distance can be from about 4 mm to about 16 mm.
- the second tracking distance can be about 10 mm.
- the injection mold 27 includes an upper mold body 33 and a lower mold body 34 which collectively define a mold cavity 28 when the mold bodies 33 , 34 are closed in a conventional manner.
- Injection ports, sprues, runners, etc. for injecting thermoplastic material into the cavity 28 are all conventional and are not shown in FIGS. 4 through 7 of the drawings.
- the mold cavity 28 of the mold 27 includes respective upper and lower cavity portions 29 , 30 , respectively.
- the upper cavity portion 29 of the mold cavity 28 is defined by a central quadrangular uni-planar surface 35 ( FIGS. 4 and 5 ), an innermost peripheral surface 36 , a uppermost planar surface 37 lying in a plane parallel to, but axially spaced from, the plane of the central quadrangular surface 35 , and an outermost peripheral surface 38 which merges with a peripheral parting surface 43 .
- the cavity portion 30 is defined by a central quadrangular uni-planar surface 39 ( FIGS. 4 and 5 ) in substantially spaced opposing relationship to the central quadrangular uni-planar surface 35 of the cavity portion 29 , an innermost peripheral surface 40 , and a lowermost planar surface 41 lying in a plane parallel to, but axially spaced from, the plane of the central quadrangular surface 39 .
- the planar surface 41 has a peripheral portion 42 which abuts the parting surface 43 of the upper mold body 33 when the upper and lower mold bodies 33 , 34 , respectively, are closed ( FIG. 6 ).
- the peripheral surface 40 can be designed to include diametrically opposite bayonet lugs/slots, preferably spaced 90 degrees from each other or conventional threads, but no matter the character of the peripheral surface 40 , the function thereof is to permit the rapid attachment and detachment of the solar module 5 respectively to and from the injection mold 27 in a conventional manner.
- the solar module 5 In the open position of the mold bodies 33 , 34 ( FIG. 4 ), the solar module 5 is seated atop and upon the central quadrangular uni-planar surface 39 of the mold body 34 in the manner illustrated in FIG. 5 with the peripheral edge portion 20 projecting an equal distance beyond the peripheral surface 40 .
- the mold bodies 33 , 34 are closed in the manner illustrated in FIG. 6 . In the closed position, the solar module 5 is clamped between surfaces 35 , 39 and a peripheral cavity 31 is defined.
- thermoplastic material is injected into the peripheral cavity 31 resulting in the formation of the encapsulation frame 8 which covers peripheral edge portions 20 and 19 of the second facial surface 3 and the first facial surface 1 of the solar module 5 respectively.
- the encapsulation frame 8 seals the edge 7 of the photovoltaic device 4 .
- the encapsulation frame 8 also seals the edges 22 and 21 of the back glass 6 and the front glass 2 of the solar module 5 respectively.
- the solar module 5 is framed.
- the edge-encapsulated solar module 5 can remain seated upon the mold body 34 ( FIG. 7 ) or can be withdrawn therefrom.
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Abstract
A solar module including a front support, back support and absorber layer are disclosed. The solar module is framed by an encapsulation frame.
Description
- This application claims priority to U.S. Provisional Patent Application No. 61/122,571, filed on Dec. 15, 2008, which is incorporated by reference in its entirety.
- This invention relates to a solar module with encapsulated edge and the methods of making it.
- Solar modules have photovoltaic devices to generate electricity. Photovoltaic devices are formed between the front glass and the back glass of the solar module and edge-sealed. The tracking distance is the distance between the edge of the photovoltaic device and the outer edge of the seal. For reasons of safety, a certain tracking distance is required, which will make the peripheral portion of the solar module unusable.
- In one aspect, an edge-encapsulated solar module may include a solar module and an encapsulation frame. The solar module has a back support, a front support, and an absorber layer between the front support and the back support. The encapsulation frame surrounding the solar module, where the encapsulation frame contacts an edge portion of the back support and an edge portion of the front support. The encapsulation frame may additionally contact a peripheral edge portion of a facial surface of the front support and a peripheral edge portion of a facial surface of the back support. The back and front support can include glass respectively. The encapsulation frame can include rubber, plastic, thermoplastic elastomer, or EPDM rubber.
- In one aspect, a first tracking distance of solar module is a distance along a surface of the back support between an edge of the encapsulation and an edge of the absorber layer, and a second tracking distance is a distance along a surface of the front support between an edge of the encapsulation and an edge of the absorber layer. The first tracking distance and the second tracking distance can be at least 4 millimeters, about 4 millimeters to 50 millimeters, about 4 millimeters to 16 millimeters, or about 10 millimeters.
- In another aspect, a method of making an edge-encapsulated solar module includes framing a photovoltaic device with an encapsulation frame contact an edge portion of each of a front support, the back support, and the photovoltaic device. The method can further include forming an absorber layer on the first support and positioning the second support on the absorber layer. The framing can include injection molding the encapsulation frame. The framing can include plastic extrusion of the encapsulation frame. The back and front support can include glass respectively. The framing can include covering a peripheral edge portion of each of the first support, the photovoltaic device, and the second support with rubber, plastic, thermoplastic elastomer, or EPDM rubber. The framing can further include a step of positioning a first edge of the encapsulation at a predetermined first tracking distance from the photovoltaic device, wherein the first tracking distance is a distance along a surface of the back support between an edge of the encapsulation and an edge of the absorber layer. The framing can further include a step of positioning a second edge of the encapsulation at a predetermined second tracking distance from the photovoltaic device, wherein the second tracking distance is a distance along a surface of the front support between an edge of the encapsulation and an edge of the absorber layer. The first tracking distance and the second tracking distance can be at least 4 millimeters, about 4 millimeters to 50 millimeters, about 4 millimeters to 16 millimeters, or about 10 millimeters.
- The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
-
FIG. 1 is a cross-sectional view of an embodiment of a solar module with encapsulated edge. -
FIG. 2 is a perspective view of an embodiment of a solar module with encapsulated edge shown inFIG. 1 . -
FIG. 3 is a cross-sectional view of an embodiment of a solar module with encapsulated edge. -
FIG. 4 is a vertical cross-sectional view taken through an injection mold of the present invention, and illustrates upper and lower mold bodies in their open position with each defining a cavity portion which in the closed position of the mold defines a mold cavity for forming the encapsulation of the instrument cover ofFIG. 1 . -
FIG. 5 is a vertical cross-sectional view taken through the mold ofFIG. 4 , and illustrates the solar module positioned upon the lower mold body incident to the closing of the mold bodies. -
FIG. 6 is a vertical cross-sectional view of the mold ofFIGS. 4 and 5 , and illustrates the mold in its closed position and a peripheral cavity defined thereby into which projects a peripheral edge of the solar module. -
FIG. 7 is a vertical cross-sectional view of the mold ofFIGS. 4 through 6 , and illustrates thermoplastic material injected into the cavity and encapsulating an edge of the solar module to form a continuous encapsulation. - To minimize the unusable peripheral portion of the solar module and maintain the certain tracking distance at the same time, the solar module is framed with an encapsulation. The tracking distance can be added up along the surface of front glass or back glass to the required distance. Therefore, the photovoltaic device can be brought closer to the edge of the glass, resulting in higher efficiency of the solar module.
- Referring to
FIG. 1 andFIG. 2 as an embodiment of present invention, an edge-encapsulatedsolar module 5 may include a back support such asback glass 6, a front support such asfront glass 2, and aphotovoltaic device 4, which can include a semiconductor absorber layer that converts solar energy to electricity. Theback glass 6 has a secondfacial surface 3 of thesolar module 5. Thefront glass 2 has a firstfacial surface 1 of thesolar module 5. Theback glass 6 can have anedge 22. Thefront glass 2 can have anedge 21. Thephotovoltaic device 4 can be formed between theback glass 6 and thefront glass 2. Thephotovoltaic device 4 can have anedge 7. The edge-encapsulatedsolar module 5 can have aperipheral encapsulation frame 8. Theencapsulation frame 8 can form a frame surrounding thesolar module 5. Theencapsulation frame 8 can encapsulateperipheral edge portions facial surface 1 and the secondfacial surface 3 of thesolar module 5 respectively. Theencapsulation frame 8 can seal theedge 7 of thephotovoltaic device 4. Theencapsulation frame 8 can also encapsulate theedges back glass 6 and thefront glass 2 of thesolar module 5 respectively. Theencapsulation frame 8 may cover a minimal portion of the firstfacial surface 1 of thefront glass 2 of thephotovoltaic module 5 so as not to diminish the efficiency of the module while protecting the module edge. Theencapsulation frame 8 can be made of plastic, rubber, or thermoplastic elastomer, such as ethylene-vinyl acetate (EVA). In a certain embodiment, theencapsulation frame 8 can be made of EPDM rubber. - Referring to
FIG. 1 , a first tracking distance is the distance from the point whereencapsulation frame 8 meets secondfacial surface 3, along firstfacial surface 3 toedge 22, then alongedge 22 to absorberlayer edge 7. The first tracking distance created whenencapsulation frame 8 is installed is a minimum distance along which an electrical charge would have to travel to reach a person or component contactingback glass 6 ofsolar module 5. The first tracking distance can be determined by the design ofencapsulation frame 8. The first tracking distance can be at least 4 mm, for example in the range of about 4 mm to about 50 mm. The first tracking distance can be from about 4 mm to about 16 mm. The first tracking distance can be about 10 mm. - In continuing reference to
FIG. 1 , a second tracking distance is the distance from the point whereencapsulation frame 8 meets firstfacial surface 1, along secondfacial surface 1 toedge 21, then alongedge 21 to absorberlayer edge 7. The second tracking distance created whenencapsulation frame 8 is installed is a minimum distance along which an electrical charge would have to travel to reach a person or component contactingfront glass 2 ofsolar module 5. The second tracking distance can be determined by the design ofencapsulation frame 8. The second tracking distance can be at least 4 mm, for example in the range of about 4 mm to about 50 mm. The second tracking distance can be from about 4 mm to about 16 mm. The second tracking distance can be about 10 mm. - Referring to
FIG. 3 as another embodiment of present invention, an edge-encapsulatedsolar module 17 may include a back support, such asback glass 13, a front support, such asfront glass 10, aphotovoltaic device 11 including a semiconductor absorber layer, and anadditional layer 12. Thelayer 12 can be a semiconductor layer. Thelayer 12 can be a barrier layer, such as a SiO2 barrier layer or a SiNx barrier layer. Thefront glass 10 has a firstfacial surface 9 of thesolar module 17. Thefront glass 10 can have anedge 24. Theback glass 13 has a secondfacial surface 14 of thesolar module 17. Theback glass 13 can have anedge 25. The firstphotovoltaic device 11 and theadditional layer 12 can be formed between theback glass 13 and thefront glass 10. Firstphotovoltaic device 11 can have anedge 16. Theadditional layer 12 can have anedge 15. The edge-encapsulatedsolar module 17 can have aperipheral encapsulation frame 18. Theencapsulation frame 18 can form a frame surrounding thesolar module 17. Theencapsulation frame 18 can coverperipheral edge portions first surface 9 and thesecond surface 14 of thesolar module 17 respectively. Theencapsulation frame 18 can seal theedge 16 of firstphotovoltaic device 11 and theedge 15 oflayer 12.Encapsulation frame 18 can also seal theedges back glass 13 and thefront glass 10 of thesolar module 17 respectively. Theencapsulation frame 18 may cover a minimal portion of thefirst surface 9 of thefront glass 10 ofphotovoltaic module 17 so as not to diminish the efficiency of the module while protecting the panel edge. Theencapsulation frame 18 can be made of plastic, rubber, or thermoplastic elastomer. In a certain embodiment, theencapsulation frame 18 can be made of EPDM rubber. - Referring to
FIG. 3 , a first tracking distance is the distance from the point whereencapsulation frame 18 meets secondfacial surface 14, along secondfacial surface 14 to edge 25, then alongedge 25 toadditional layer edge 15, alongadditional layer edge 15 tophotovoltaic device 11, to the absorber layer. The first tracking distance created whenencapsulation frame 18 is installed is a minimum distance along which an electrical charge would have to travel to reach a person or component contacting backglass 13 ofsolar module 17. The first tracking distance can be determined by the design ofencapsulation frame 18. The first tracking distance can be at least 4 mm, for example in the range of about 4 mm to about 50 mm. The first tracking distance can be from about 4 mm to about 16 mm. The first tracking distance can be about 10 mm. - In continuing reference to
FIG. 3 , a second tracking distance is the distance from the point whereencapsulation frame 18 meets firstfacial surface 9, along firstfacial surface 9 to edge 24, then alongedge 24 toabsorber layer edge 16. The second tracking distance created whenencapsulation frame 18 is installed is a minimum distance along which an electrical charge would have to travel to reach a person or component contactingfront glass 10 ofsolar module 17. The second tracking distance can be determined by the design ofencapsulation frame 18. The second tracking distance can be at least 4 mm, for example in the range of about 4 mm to about 50 mm. The second tracking distance can be from about 4 mm to about 16 mm. The second tracking distance can be about 10 mm. - Referring to
FIG. 4 throughFIG. 7 as an embodiment of present invention of making edge-encapsulated solar module, theinjection mold 27 includes anupper mold body 33 and alower mold body 34 which collectively define amold cavity 28 when themold bodies cavity 28 are all conventional and are not shown inFIGS. 4 through 7 of the drawings. - The
mold cavity 28 of themold 27 includes respective upper andlower cavity portions - The
upper cavity portion 29 of themold cavity 28 is defined by a central quadrangular uni-planar surface 35 (FIGS. 4 and 5 ), an innermostperipheral surface 36, a uppermostplanar surface 37 lying in a plane parallel to, but axially spaced from, the plane of the centralquadrangular surface 35, and an outermostperipheral surface 38 which merges with aperipheral parting surface 43. - The
cavity portion 30 is defined by a central quadrangular uni-planar surface 39 (FIGS. 4 and 5 ) in substantially spaced opposing relationship to the central quadrangularuni-planar surface 35 of thecavity portion 29, an innermostperipheral surface 40, and a lowermostplanar surface 41 lying in a plane parallel to, but axially spaced from, the plane of the centralquadrangular surface 39. Theplanar surface 41 has aperipheral portion 42 which abuts theparting surface 43 of theupper mold body 33 when the upper andlower mold bodies FIG. 6 ). In certain embodiments, theperipheral surface 40 can be designed to include diametrically opposite bayonet lugs/slots, preferably spaced 90 degrees from each other or conventional threads, but no matter the character of theperipheral surface 40, the function thereof is to permit the rapid attachment and detachment of thesolar module 5 respectively to and from theinjection mold 27 in a conventional manner. - In the open position of the
mold bodies 33, 34 (FIG. 4 ), thesolar module 5 is seated atop and upon the central quadrangularuni-planar surface 39 of themold body 34 in the manner illustrated inFIG. 5 with theperipheral edge portion 20 projecting an equal distance beyond theperipheral surface 40. Themold bodies FIG. 6 . In the closed position, thesolar module 5 is clamped betweensurfaces peripheral cavity 31 is defined. Such closing techniques are conventional in the art, and suffice it to say that themold bodies solar module 5 such that a peripheral portion of thecavity 28 is in part set off and defined by theperipheral edge portion 20 of thesolar module 5 projecting therein, as is clearly illustrated inFIG. 6 . - As is best illustrated in
FIG. 7 of the drawings, thermoplastic material is injected into theperipheral cavity 31 resulting in the formation of theencapsulation frame 8 which coversperipheral edge portions facial surface 3 and the firstfacial surface 1 of thesolar module 5 respectively. Theencapsulation frame 8 seals theedge 7 of thephotovoltaic device 4. Theencapsulation frame 8 also seals theedges back glass 6 and thefront glass 2 of thesolar module 5 respectively. Upon solidification of theencapsulation frame 8, thesolar module 5 is framed. Upon the opening of themold bodies solar module 5 can remain seated upon the mold body 34 (FIG. 7 ) or can be withdrawn therefrom. - A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. It should also be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various preferred features illustrative of the basic principles of the invention.
Claims (19)
1. An edge-encapsulated solar module comprising:
a solar module comprising a back support, a front support, and an absorber layer between the front support and the back support; and
an encapsulation frame surrounding the solar module, wherein the encapsulation frame contacts an edge portion of the back support and an edge portion of the front support.
2. The solar module of claim 1 , wherein the encapsulation frame additionally contacts a peripheral edge portion of a facial surface of the front support and a peripheral edge portion of a facial surface of the back support.
3. The solar module of claim 1 , wherein the front support comprises a glass.
4. The solar module of claim 1 , wherein the back support comprises a glass.
5. The solar module of claim 1 , wherein the encapsulation frame comprises a rubber.
6. The solar module of claim 1 , wherein the encapsulation frame comprises a plastic.
7. The solar module of claim 1 , wherein a first tracking distance is a distance along a surface of the back support between an edge of the encapsulation and an edge of the absorber layer, and a second tracking distance is a distance along a surface of the front support between an edge of the encapsulation and an edge of the absorber layer.
8. The solar module of claim 7 , wherein the first tracking distance is at least 4 millimeters.
9. The solar module of claim 7 , wherein the second tracking distance is at least 4 millimeters.
10. A method of making an edge-encapsulated solar module comprising:
framing a photovoltaic device with an encapsulation frame contacting an edge portion of each of a front support, a back support, and the photovoltaic device.
11. The method of claim 10 , further comprising forming an absorber layer on the first support and positioning the second support on the absorber layer.
12. The method of claim 10 , wherein framing includes injection molding the encapsulation frame.
13. The method of claim 10 , wherein framing includes plastic extrusion of the encapsulation frame.
14. The method of claim 10 , wherein framing includes covering a peripheral edge portion of each of the first support, the photovoltaic device, and the second support with rubber.
15. The method of claim 10 , wherein framing includes covering a peripheral edge portion of each of the first support, the photovoltaic device, and the second support with plastic.
16. The method of claim 10 , wherein framing further comprises the step of positioning a first edge of the encapsulation at a predetermined first tracking distance from the photovoltaic device, wherein the first tracking distance is a distance along a surface of the back support between an edge of the encapsulation and an edge of the absorber layer.
17. The method of claim 10 , wherein framing further comprises the step of positioning a second edge of the encapsulation at a predetermined second tracking distance from the photovoltaic device, wherein the second tracking distance is a distance along a surface of the front support between an edge of the encapsulation and an edge of the absorber layer.
18. The method of claim 10 , wherein the first tracking distance is at least 4 millimeters.
19. The method of claim 10 , wherein the second tracking distance is at least 4 millimeters.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US12/636,689 US20100193029A1 (en) | 2008-12-15 | 2009-12-11 | Solar Module with Encapsulated Edge |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US12257108P | 2008-12-15 | 2008-12-15 | |
US12/636,689 US20100193029A1 (en) | 2008-12-15 | 2009-12-11 | Solar Module with Encapsulated Edge |
Publications (1)
Publication Number | Publication Date |
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US20100193029A1 true US20100193029A1 (en) | 2010-08-05 |
Family
ID=42288070
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US12/636,689 Abandoned US20100193029A1 (en) | 2008-12-15 | 2009-12-11 | Solar Module with Encapsulated Edge |
Country Status (10)
Country | Link |
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US (1) | US20100193029A1 (en) |
EP (1) | EP2377236A1 (en) |
JP (1) | JP2012512545A (en) |
KR (1) | KR20110104513A (en) |
CN (1) | CN102318083A (en) |
AU (1) | AU2009330497A1 (en) |
MX (1) | MX2011006414A (en) |
TW (1) | TW201031003A (en) |
WO (1) | WO2010074941A1 (en) |
ZA (1) | ZA201104454B (en) |
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DE102011053583A1 (en) * | 2011-09-14 | 2013-03-14 | Reis Group Holding Gmbh & Co. Kg | Plate-shaped module and method for producing a frame for such |
CN103201853A (en) * | 2010-09-02 | 2013-07-10 | 第一太阳能有限公司 | Solar module with light-transmissive edge seal |
WO2014071341A1 (en) * | 2012-11-05 | 2014-05-08 | First Solar, Inc | Solar modules and methods of forming the same |
USD733645S1 (en) | 2013-06-28 | 2015-07-07 | Dow Global Technologies Llc | Corner connector for a photovoltaic module frame |
USD747262S1 (en) | 2013-06-28 | 2016-01-12 | Dow Global Technologies Llc | Photovoltaic back panel |
CN105576057A (en) * | 2014-10-31 | 2016-05-11 | 比亚迪股份有限公司 | Solar cell module and preparation method thereof |
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WO2014166064A1 (en) * | 2013-04-09 | 2014-10-16 | Sun wen-yu | Plastic outer frame, solar photovoltaic module having plastic outer frame and manufacturing method for same |
JP6308901B2 (en) * | 2014-07-15 | 2018-04-11 | 三菱電機株式会社 | Solar cell module and solar cell module manufacturing apparatus |
CN107221572A (en) * | 2017-05-03 | 2017-09-29 | 黄淮学院 | It is a kind of based on carbon nano-structured solar cell |
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- 2009-12-07 CN CN2009801567187A patent/CN102318083A/en active Pending
- 2009-12-07 EP EP09835499A patent/EP2377236A1/en not_active Withdrawn
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Also Published As
Publication number | Publication date |
---|---|
EP2377236A1 (en) | 2011-10-19 |
AU2009330497A1 (en) | 2011-07-07 |
MX2011006414A (en) | 2011-07-13 |
ZA201104454B (en) | 2012-02-29 |
TW201031003A (en) | 2010-08-16 |
JP2012512545A (en) | 2012-05-31 |
CN102318083A (en) | 2012-01-11 |
KR20110104513A (en) | 2011-09-22 |
WO2010074941A1 (en) | 2010-07-01 |
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